Foam mattress



July 30, 1963 J. J. wETzLER 3,099,021

FOAM MATTRESS Filed May 28, 1957 INVENTOR.

July 30, 1963 J. J. wETzLER 3,099,021

FOAM MATTRESS 5 Sheets-Sheet 2 Filed May 28, 1957 July 30, 1963 J. J. wETzLER 3,099,021

FOAM MATTRESS Filed May 28. 195'? 3 sheets-sheet s United States Patent O 3,099,021 FOAM MATrREss Justin J. Wetzler, Evanston, Ill., assigner to The Eng-- lander Company, Inc., Chicago, Ill., a corporation of Delaware Filed May 28, 1957, Ser. No. 662,085 6 Claims. (Cl. 5-353) This invention relates to a mattress, pad or cushion comprising a plurality of springs embedded in a resilient rubber-like foam structure. The invention also pertains Ito methods and apparatus for making such a mattress, pad or cushion.

The resilient mbber-like foam struct-ure referred to hereinabove is suitably one of the conventional urethane foams prepared by the reaction of la po'flyisocyanate (usually, .a diisocyanate) with an organic substance having a plurality of groups or radicals each containing reactive hydrogen, 4for instance, a polyester or a polyether or `one of the substances disclosed in the patent to Hanford et al. No. 2,284,896. Note the article .entitled Polyethers for Urethane Foams `on page 78 of January 2l, 1957, issue of Chemical and Engineering News. Methods of making specific foams are disclosed, for instance, i-n the patents to Simon et Ial. Nos. 2,577,279, 2,577,280, 2,591,884, 2,602,783 2,698,838, and 2,764,566; in the patent to Hill No. 2,726,219; land in the patent to Reis No. 2,779,689. rIIhe chemical processes and reactions involved in the formation of urethane foams 'are wel-l known to those skilled in the art and per se form no part of the present invention. Hence, Ino further reference will be made to the chemistry 'of urethane Ifoams except to note, at this time, that urethane foams may be formed by mixing lappropriate reactants and depositing the resultant mixture on a surface as a thin layer. Then a chemical reaction occurs accompanied by the evolution of gas. Thus, a layer originally one-half inch thick may foam up to a thickness lof perhaps tour inches. This foaming action may be completed within 3 .or 4 minutes. Transformaftion of the :originally liquid reactant mixture into a more or less resilient, rubber-like cellular solid takes place concurrently wit-h the gas forming foaming reaction.

In making 1a mattress, pad or cushion according to the present invention, a spring structure is rst provided. 'I'he individual springs of this spring structure are then each` covered with a water resistant l-.my coating which bridges the convolutions of the individual springs, so that each individual spring is enclosed -within a separate iilm envelope. Such coating compositions land spraying or dipping methods for 'applying the same are conventional and are well known to those skilled in the art. Examples are given, for instance, in the patents to Phillips et al. No. 2,394,101 and to Pineles No. 2,441,227. 'The compositions in question fonm per se no part of the present invention.

When `the yabove noted spring structure has -been provided with a protective iilni envelope around each individual spring, the spring structure is embedded within a urethane foam slab or layer. 'Ilhe resulting unitary structure may be used as such a mattress, pad or cushion. Or, if desired, `other 4and'zEurt-her layers of padding may be provided therearound, and the structure may be enclosed within any desired cover or casing.

Other and further features of `the present invention wil-l become apparent from the following `description and appended claims Ias illustrated ,by the accompanying drawings which show diagrammatically and by Way of examples mattresses according to the present invention and methods and Aapparatus for making the same, land in which drawings:

FIG. l is a vertical longitudinal cross` sectional view 3,099,021 Patented July 30, 1963 taken kalong the line 1 1 of FIG. 2 4and showing appparatus for making a mattress according to the present invention;

FIG. 2 is ya cross sectional view taken along the line 2-2 of FIG. l;

FIG. 3 is an enlarged fragmentary cross sectional view taken along the line 3 3 of FIG. 1;

FIG. 4 is a fragmentary View similar to FIG. y1 and showing \a modification of one `detail in the apparatus of FIG. 1;

FIG. 5 is a perspective view of a coil spring enclosed within a film envelope preparatory 'to incorporation with a mattress unit according to the method illustrated in FIGS, 1-3;

FIG. 6 is Ia cross sectional View taken along the line 6 6 of FIG. 5;

FIG. 7 is an enlarged lfragmentary vertical cross sectional view through `a mattress made according to the method of FIGS. l-3 land including coils such as that illustrated in FIGS. 5 and 6;

FIG. 8 is 'a `fragmentary plan View showing a plurality of coil springs interconnected to fo-rm `a unit suitable for interconnecting within a mattress;

FIG. 9 is a fragmentary cross sectional view taken 'along the line )f--9` of FIG. 8 and shows a mattress incorporating the interconnected springs of FIG. 8;

IFIG. 10 is a view similar to FIG. -8 but shows a spring unit of slightly dilierent construction;

FIG. 1.1 is a fragmentary cross sectional View taken along the line 11-11 of FIG. 10 and shows a mattress incorporating the spring unit of FIG. l0;

FIG. l2 is a perspective view of a coil spring held -in slightly compressed condition and enclosed Within an envelope preparatory to incorporation with la matress;

FIG. 13 is a Afragmentary plan view showing another plurality of coil springs interconnected to form `a -unit suitable for incorporation within -a mattress;

FIG. 14 is a cross sectional view taken along the line 14-14 `of FIG. 13 and shows a mattress incorporating the interconnected springs of FIG. 13;

FIG. 15 is a fragmentary plan view showing another set of coil springs interconnected for incorporation in va mattress;

FIG. 16 is a cross sectional view taken along the line 16-16 of FIG. 15 and shows a mattress incorporating the springs of FIG. 15;

FIG. 17 is a fragmentary plan View of a plurality of coil Vsprings tied together preparatory to incorporation within a mattress;

FIG. 18 is a cross sectional view taken Ialong the line 18-18 of FIG. 17 `and shows a mattress incorporating the springs of FIG. 17;

FIG. 19 is a lfragmentary plan view showing a plurality of coil springs interconnected preparatory to incorporation within a mattress;

FIG. 20 is a cross sectional view taken along the line 20-20 of fFIG. 19 and shows a mattress including the springs of FIG. 19; and

FIG. 21 is a longitudinal vertical 4cross sectional View similar to FIGS. 14, 16, 18 and 20 and showing a mattress similar to that made `according to the methods of FIGS. 1-3 and including an outer layer of padding and a mattress cover or ticking.

Reference -is now made to FIGS. 1 3 which show apparatus according to the present invention including a lower belt 10 travelling over horizontal spaced rollers 12 and 14 and supported therebetween by a lower shoe 16. Suitable conventional means are provided for causing the belt 10 to travel from the left to the right. An upper bel-t 18 moving over rollers 20 and '22 likewise is caused to move from left to right by any suitable conventional means. The upper roller 22 is aligned vertically with the lower roller 14. The upper roller 20 is oilset to the right with respect to the lower roller 12. A shoe 24 holds the horizontal portion of the belt `18 against upward displacement. A pair of vertical sidewall members 26 and 23 serve to complete enclosure of the space between the lower belt and the upper belt 18. A hopper 38 serves to discharge material received from a conduit 32 onto the lower belt 10 to the left of the roller 2G.

In the operation of the apparatus of FIGS. 1-3, a strip of urethane foam rubber 34 is caused to travel along the belt 10 over and above the horizontal reach of the latter belt and another strip 36 of urethane foam rubber is caused to travel along and below the horizontal reach of the belt 18. Sets of interconnected coil springs generally indicated at 40 are introduced between the urethane foam rubber strips 34 and 36 for travel therewith between the sidewalls or guides 26 and 28.

As s'hown in FIG. 1 each spring assembly 40 4is initially disposed on Vthe urethane foam strip 34. While the spring assembly 49 is in this position, a urethane foam forming mixture 42 is deposited on the strip 34 from the hopper 38. Originally, this more or less viscous but still liquid lfoam forming mixture 42 does not extend to the top of the spring assembly 40. However, as the latter travels from kleft to right, the formation of `foam in the mixture 42 causes the latter to rise to the -top of the spring yassembly 40 and into contact with the underside of the upper urethane foam strip 36. It will be noted that the lower rollers 12 and 14 and the upper rollers and 22 are spaced apart so that the spring assembly 40 will tit exactly between -the two urethane foam rubber strips 34 and 36, the latter being held in position by the two shoes 16 and 24.

The spring yassembly 40 includes upper and lower wire frames 44 `and 46 extending therearound; a plurality of individual coil springs 48; and upper and lower sets of crossing or intersecting wires 50 interconnecting -the .coil springs 48 with each other and with the frames 44 and 46. Further, as shown in FIGS. 5 and 6, each individual coil spring 48 is enveloped by `a i-lm 52.

The resulting mattress structure is illustrated in IFIG. 7 as including coil springs 48 each individually enveloped by a nlm 52 .and all interconnectedV to each other and to the frames 44 and 46 by means of -crossing wires 50 to form a spring assembly 40 embedded within an integral urethane foam structure made up of the lower Istrip 34, the upper strip 36 and the material 42 deposited from the hopper 30 and, when completely polymerized, bonded to and connecting the two -strips 34 and 36 -to form therewith an integral foam structure.

It should be understood that the rubber strips 34 and 36 may be continuous so that as successive spring assemblies 40 are fed therebetween and foam forming liquid 42 is deposited on the lower strip 34, there is formed Ia continuous foam structure embedding successive spring assemblies 40 from which individual mattresses may be isolated by severing this structure between the spaced ends of the spring assemblies 40. However, if desired, it is also possible Ito make the foam strips 34 and 36 discontinuous, individual strip uni-ts being fed in pairs between the belts 10 and -18 in proper synchronization with spring assemblies 40 to form a continuous strip held together only by foam forming material 42 extending between the `spaced ends of successive spring assemblies 40.V Then, to isolate individual mattresses, it is only necessary to sever the connecting foam material 42 between the spaced ends of the spring assemblies 40.

Ordinarily, the spring assembly 40 is completely assembled from its constituent parts (coils 48, wires 50 and -frames 44 and 46) and thereafter the coil springs 48 are dipped or sprayed with a film forming material to enclose each spring 48 within a tlmy envelope 52.

The foam `forming material 42 can ybe deposited on the spring assembly 4t) and the lower foam strip 34 .by any suitable conventional means. As shown in FIG. 4, such deposition may also be elected by means of a pair of spray nozzles 60 and 62 each serving to deposit, in one and the same area, for mutual admixtu-re, two components which when mixed constitute a foaming urethane forming composition. Y

Any desired conventional type of spring lassembly adapted for use in .a mattress, pad or cushion may be embedded within a urethane foam structure utilizing the apparatus and method .disclosed hereinabove. Reference is made to FIGS. 8-20 as showing mattresses, pads or cushions including various types of conventional spring assemblies embedded within an integral urethane foam structure, each individual coil spring i-n said assemblies being enclosed within an individual -iilrny envelope.

-As shown in FIGS. 8 and 9, a plurality of coil springs 64, each enclosed within .a iilmy envelope 66, are held in assembled relationship within upper and lower wire frames 68 and 70 by means of longitudinally extending Wires 72. The springs 64 are arranged in spaced rows, the springs i-n each row lbeing close together. The wires 70 extend transversely of these rows of springs. Short wires 76 tie the springs 64 to t-he wires 72.

FIGS. l0 and 11 illustrate hour lglass shaped coil springs 80 each enveloped by an individual ilm 82 and held within upper and lower wire frames 84 and 86 by means of wire coils 88 engaging pairs of closely spaced coils 80 which are arranged similarly to the coils 64 of FIG. 8.

FIG. 12 shows a coil spring 90 of barrel shape held in slightly compressed state by means of a tape 92 crisscrossing through the center of the coil an-d extending vertically along opposite sides of the coil. This structure is enclosed within a iilmy envelope 94 and may .be assembled into spring assemblies similarly to the coil 48 of FIGS. 5 land 6.v

FIGS. 13 and 14 show hour glass shaped springs 100 each enclosed within a iilmy envelope 102 and held within upper and lower frames 104 and 106 by means of crossing pieces of wire .coil 108 extending lbetween diagonally opposed adjacent coils 100.

FIGS. 15 and 16 show hour glass shaped coil springs 110 each enclosed within a lmy envelope 112 and held in -assembled relationship within upper and lower frames 114 and 116 by means of intersecting upper and lower tapes 118. The springs 110 are held in'slightly cornpressed state by looped wires 119 extending within the center of each spring 110 between the upper and lower tapes 118.

FIGS. 17 and 18 show hour glass shaped coils 120 l each enclosed within a iilmy envelope 122 and all held Veach enclosed within a filmy envelope 132 and all held in spaced assembled relationship within a frame 134 extending at about a middle level by steel tapes 136'.

' FIG. 2l shows a mattress including an integral urethane foam structure 140 and coil springs 142 each enclosed within a lmy envelope 144 embedded within the foam structure 140 and held in -assembled relationship within upper and .lower -frames 146 and 148 by intersecting wires 150. The mattress further includes padding 152 and an outer cover or ticking v154.

Many details may be varied without `departing from the principles of this invention and it is therefore not my intention to limit the patent granted on this invention otherwise than necessitated by the scope of the appended claims.

The invention is claimed as follows:

1. A mattress comprising a plurality of coil springs de- Y lining a network of confluent spaces, an individual lmy envelope enclosing each coil spring, and an integral resilient cellular pad foamed .in place within said network of spaces to encircle said springs.

2. A mattress according to claim 1 further comprising means interconnecting said coil springs, said means also being embedded in said pad.

3. A mattress according to claim 2 in which said means comprise a frame extending -around said springs and Wires :connecting said springs to each other and to said frame.

4. A mattress comprising a plurailty of coil springs disposed in a predetermined pattern, an individual lmy envelope enclosing each of said coil springs, said springs being disposed so as to define a network of confluent spaces therebetween, and a resilient cellular pad foamed in place within said network spaces and encircling all of said springs, said pad including portions intimately conforming to the iilmy envelopes enclosing each of the springs.

5. A mattress comprising: a plurality of coil springs; an individual ilmy envelope enclosing each coil spring; a pair of resilient cellular strips sandwiching said coil springs; and a resilient cellular pad foamed in place about said springs vand between said strips, combining said strips into a homogeneous entity enveloping said springs.

6. A mattress comprising: a plural-ity of coil springs; an individual lmy envelope enclosing each coil spring; a pair of resilient cellular prefoamed urethane foam strips sandwiching said coil springs; and 'a resilient cellular urethane .foam pad `foamed in place about said lsprings and between said strips, combining said strips into a homogeneous entity enveloping said springs.

References Cited in the file of this patent UNITED STATES PATENTS 1,321,095 Genge Nov. 11, 1919 1,949,175 Netzel Feb. 27, 1934 2,069,589 Meijling et al. Feb. 2, 1937 2,446,775 Marsack Aug. 10, 1948 2,529,830 Bierer Nov. 14, 1950 2,615,180 Woller Oct. 28, 1952 2,688,152 Marco Sept. 7, 1954 FOREIGN PATENTS 108,871 Australia Oct. 20, 1939 143,473 Australia Sept. 18, 1951 

1. A MATTRESS COMPRISING A PLURALITY OF COIL SPRINGS DEFINING A NETWORK OF CONFLUENT SPACES, AN INDIVIDUAL FILMY ENVELOPE ENCLOSING EACH COIL SPRING, AND AN INTEGRAL RESILIENT CELLULAR PAD FOAMED IN PLACE WITHIN SAID NETWORK OF SPACES TO ENCIRCLE SAID SPRINGS. 